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PRICE 25 CENTS 



MACHINERY’S REFERENCE BOOK NO. 114 

PUBLISHED BY MACHINERY. NEW YORK 


MACHINE FORGING 


MACHINES AND METHODS USED IN THE FORM¬ 
ING, WELDING AND UPSETTING OF 
MACHINE PARTS 

BY DOUGLAS T. HAMILTON 





MACHINERY’S REFERENCE BOOKS 

This book is one of a remarkably successful series of 25-cent Reference Books 
listed below. These books were originated by Machineky and comprise a complete 
working library of mechanical literature, each book covering one subject. The price 
of each book is 25 cents (one shilling) delivered anywhere in the world. 


CLASSIFIED LIST OF REFERENCE BOOKS 



GENERAL MACHINE SHOP 

PRACTICE 

No. 

101. 

No. 

No. 

7. 

10. 

Lathe and Planer Tools. 
Examples of Machine Shop 

Practice. 

No. 

102. 

No. 

£5. 

Deep Hole Drilling. 



No. 

103. 

No. 

.32. 

Screw Thread Cutting. 





No. 

48. 

Files and Filing. 



No. 

104. 

No. 

60. 

Principles and Practice 
Maciime Tools, Part I. 

of 

Assembling 

No. 

106. 

No. 

61. 

Principles and Practice 

of 

Assembling 

No. 

106. 

No. 

67. 

Machine Tools, Part II. 
Metal Spinning. 




No. 69, Machines, Tools and Methods of Auto¬ 
mobile Manufacture. 


No. 

91. 

Operation of Machine Tools.—The Lathe, 

No. 

18. 



Part I, 

No. 

62. 

No. 

92. 

Operation of Machine Tools.—The Lathe, 





Fart II. 

No. 

53. 

No. 

93. 

Operation of Machine Tools. — Planer, 





Shaper, Slotter. 

No. 

64. 

No. 

94. 

Operation of Machine Tools.—Drilling Ma¬ 

No. 

66. 



chines. 



No. 

95. 

Operation of Machine Tools.—Boring Ma¬ 




« 

chines. 

VTa 

t 

No. 

96. 

Operation of Machine Tools.—Milling Ma¬ 

^ Ot 

•*T 

o. 



chines, Part I. 

No. 

X9* 

No. 

97. 

Operation of Machine Tools.—Milling Ma¬ 





chines, Part II. 



No. 

98. 

Operation of Machine Tools.—Grinding 

No. 

1. 



Machines. 

No. 

15. 

No. 

116. 

Manufacture of Steel Balls. 

No. 

20. 

No. 

120. 

Arbors and Work Holding Devices. 

No. 

87. 



TOOLMAKING 



No. 

21. 

Measuring Tools. 

No. 

9. 

No. 

31. 

Screw Thread Tools and Gages. 

No. 

11. 

No. 

64. 

Gage Making and Lapping. 

No. 

17. 

No. 

107. 

Drop Forging Dies and Die Sinking. 

No. 

22. 



HARDENING AND TEMPERING 

No. 

24. 

No. 

46. 

Hardening and Tempering. 

No. 

40. 

No. 

63. 

Heat-treatment of Steel. 

No. 

66. 




No. 

58. 



JIGS AND FIXTURES 

No. 

89. 

No. 

3. 

Drill Jigs. 



No. 

4. 

Milling Fixtures. 



No. 

41. 

Jigs and Fixtures, Part I. 

No. 

14. 

No. 

42. 

Jigs and Fixtures, Part II. 

No. 

16. 

No. 

43. 

Jigs and Fixtures, Part III. 

No. 

Ill, 




No. 

112, 



PUNCH AND DIE WORK 



No. 

6. 

Punch and Die Work. 



No. 

13. 

Blanking Dies. 



No. 

26. 

Modern Punch and Die Construction. 

No. 

23. 




No. 

47. 


AUTOMATIC SCREW MACHINE WORK- 

No. 

49. 

No. 

99. 

Operation of Brown & Sharpe Automatic 





Screw Machines, 



No. 

100. 

Designing and Cutting Cams for the Au¬ 

No. 

65. 



tomatic Screw Machine. 




Automatic Screw Machines. 

External Cutting Tools for Automatic 
Screw Machines. 

Internal Cutting Tools for Automatic 
Screw Machines. 

Threading Operations on Automatic 
Screw Machines. 

Knurling Operations on Automatic Screw 
Machines. 

Cross Drilling, Burring and Slotting Op¬ 
erations on Automatic Screw Machines. 

SHOP CALCULATIONS 

Shop Arithmetic for the Machinist. 

Advanced Shop Arithmetic for the Ma¬ 
chinist. 

The Use of Logarithms—Complete Log- 
^ithmic Tables. 

Solution of Triangles, Part I. 

Solution of Triangles, Part II. 

THEORETICAL MECHANICS 

First Principles of Theoretical Mechanics. 
Use of Formulas in Mechanics. 

GEARING 

Worm Gearing. 

Spur Gearing, 

Spiral Gearing. 

Bevel Gearing, 

4t 

GENERAL MACHINE DESIGN 

Designing and Cutting Cams. 

Bearings. 

Strength of Cylinders. 

Calculation of Elements of Machine De¬ 
sign. 

Examples of Calculating Designs, 
Flywheels. 

Ball Bearings. 

Helical and Elliptic Springs. 

The Theory of Shrinkage and Forced Fits. 

MACHINE TOOL DESIGN 

Details of Machine Tool Design. 

Machine Tool Drives. 

Lathe Bed Design. 

Machine Stops, Trips and Locking De¬ 
vices. 

CRANE DESIGN 

Theory of Crane Design. 

Electric Overhead Cranes. 

Girders for Electric Overhead Cranes. 

STEAM AND GAS ENGINES 

Formulas and Constants for Gas Engine 
Design. 


SEE INSIDE BACK COVER FOR ADDITIONAL TITLES 


MACHINERY’S REFERENCE SERIES 

\ » 

EACH NUMBER IS ONE UNIT IN A COMPLETE LIBRARY OF 
MACHINE DESIGN AND SHOP PRACTICE REVISED AND 
REPUBUSHED FROM MACHINERY 


NUMBER 114 


MACHINE FORGING 

» 

By Douglas tJ- Hamilton 


CONTENTS 

Machine Forging Dies and Methods ----- 3 

Welding in the P^orging Machine ------ 21 


* t) 


ropyripht, 1914, The Industrial Press, Puidlshers of Machinert, 
140-148 Lafayette Street, New York City 







« 

« « 

t 4 

< • ^ 


f 




FEB 20 1914 

©CU36908O 


CHAPTER I 


MACHINE FORGING DIES AND METHODS 

Possibly the greatest advance made of late years in forging is the 
application of machine methods to the production of engine and ma¬ 
chine parts. It is now possible to forge many parts from steel and 
wrought iron, which a few years ago could only be made from castings. 
This means a great saving of time and expense, as not only are ma¬ 
chine forged parts much more rapidly made than those made from cast 
iron or steel castings, but they also cost considerably less to manufac¬ 
ture in large quantities. In the following, interesting examples of dif¬ 
ferent types of upsets, bending and forming operations, etc., will be il¬ 
lustrated and described, together with a general description of the dies 
and tools used. This will give an idea of the remarkable possibilities 
of the upsetting and forging machine in its present-day development. 

The Upsetting and Forging Machine 

The upsetting and forging machine might be considered to a certain 
extent as a further development of the bolt and rivet making machine, 
which was originated almost a century ago; but forging machines are 
built much heavier than bolt and rivet machines and are designed 
especially to meet the demands in the production of difficult-shaped and 
heavy forgings. For the heavier types of machines, the base or main 
frame, as a rule, is made from one solid steel casting. 

A typical upsetting and forging machine designed for heavy service 
is shown in Fig. 1. The bed of this machine is made from one solid 
casting of semi-steel. In order to provide against breakage caused by 
accidentally placing work between the dies, upsetting and forging ma¬ 
chines are usually furnished with various safety devices to prevent 
serious damage to the machine. The safety device in this machine 
consists of a toggle-joint mechanism for operating the movable grip¬ 
ping-die slide. The gripping die slide A, Fig. 1, is operated by two 
cams B and 0 on the main crankshaft D. Cam B serves to close the 
dies which grip the work; cam C operates the opening mechanism for 
the dies. These cams are in contact with chilled cast-iron rolls B and 
F carried in the toggle slide G. The automatic grip relief is controlled 
by the by-pass toggle H and heavy coil spring 1. This toggle does not 
come into play until the strain is such that it would cause damage to 
the working mechanism of the machine, or in other words until the 
maximum power required to hold the movable die from springing away, 
is attained. The relief resets automatically on the back stroke of the 
machine, thus making a second blow possible without delay. 

Some idea of the gripping pressure exerted before the relief mech- 


t 


4 No. 114—MACHINE FORGING 

anisin operates is indicated in Fig. 2. This piece, which has been flat¬ 
tened between the opposing faces of the gripping dies, is a 2-inch round 
bar of 0.10 to 0.15 per cent carbon steel, 9% inches long. The flattened 
portion is 3% inches wide by 5 inches long and 23/32 inch thick. 
The piece, of course, was heated to a forging temperature before 



Ttpsetting" and Forging" Machine having a Safety 
Relief Mechanism for operating the Gripping Dies 


being placed between the opposing faces of the dies and was flat¬ 
tened to the condition shown in one squeeze. This illustrates 
a feature peculiar to this type of machine in that it can be used 
for squeezing or swaging operations, these being carried on between 
the opposing faces of the gripping dies. In many cases this allows 
work to be handled that is generally formed or flattened by the side 
shear J, which is operated from the movable die slide, being a con¬ 
tinued arm of the same casting. As a rule, the side shear is used for 
cutting off stock, and is also sometimes used for bending operations, 
suitable dies or cutting tools for this purpose being held in the movable 
slide J and stationary bracket K. 

Another type of upsetting and forging machine in which the working 
mechanism of the machine is protected from serious injury in a differ 

















MACHINE FORGING 


5 


€nt manner, is shown in Fig. 3. In this machine the safety device 
consists of a bolt A connecting the die slide B and the slide C operat¬ 
ing it. When any foreign body intercepts the gripping dies, the bolt A 
is sheared off, thus providing for a positive grip and at the same time 

furnishing a safety device 
that protects the working 
mechanism of the machine 
against serious injury. 

A good example of an 
upset forging operation 
which can be handled suc¬ 
cessfully in an upsetting 
and forging machine, is 
the castellated nut shown 
at A in Fig. 4. This type 
of nut is produced prac¬ 
tically without waste of 
stock in from two to 
three blows. The gripping dies and tools used are shown in Fig. 4, 
and also in detail in Fig. 5, where the construction of the tools can be 
more clearly seen. Referring to the latter illustration, it will be no¬ 
ticed that the dies C and D are made in two pieces. This is done 



Figr. 2. Extent to which a Bar is flattened 
between Gripping Dies of “National” Forging 
Machine before Relief operates 



Eig. 3. Ajax Upsetting and Forging Machine showing Safety or Shear 
Bolt, providing a Safety Relief for the Gripping Dies 

in order to facilitate the machining operations, and in many case^ 
it enables the dies to be made much cheaper because of the sim¬ 
plicity in construction. These dies are made from scrap driving- 








6 


No. 114—MACHINE FORGING 


axle steel which contains about 0.60 per cent carbon, and are hardened 
in the usual manner, the temper being drawn to a light straw color. 

The plunger E which upsets the end of the bar into the lower impres¬ 
sion in the dies, is made in three parts j this facilitates its construction 
and the method of manufacture. The body is made from a piece of soft 
machine steel, on the front end of which a hardened bushing F is 
held by a pin. The inside of this bushing is of a hexagon shape to 
form the sides of the nut. Screwed into the body of the punch is a 
former G which is machined to such shape that six “wings,” as shown, 
are formed around its periphery, these producing the castellated grooves 
in the head of the nut. The former G is pointed, and rough-forms the 
hole in the nut. The top punch which is used for completely punching 
the hole in the nut and at the same time severing it from the bar is 
also made from a machine steel body H into which is screwed a hard¬ 
ened steel punch 1, this being prevented from loosening by a pin 
driven through it. 



Fig. 4. Dies and Tools used in making a Castellated Nut in an Ajax 
Forging Machine in the L. S. & M. S. Railway Shops at 

Collinwood, Ohio 


The method of producing a hexagon castellated nut in a forging ma¬ 
chine is as follows: A bar of the required size (which must not exceed 
the root diameter of the thread in the finished nut) is heated in the 
furnace to a temperature of from 1400 to 1600 degrees F., depending 
upon the material, and is then brought to the forging machine and 
placed in the lower impression of the gripping dies. Then as the 
machine is operated, the lower plunger advances, upsetting the end of 
the bar and forming the excess metal into a nut of the required shape. 
The bar is now quickly removed from the lower impression, placed in 
the upper impression, and the machine again operated; whereupon the 
top plunger advances, completing the hole in the nut and attaching the 
metal thus removed to the end of the bar. These two operations are 













MACHINE FORGING 


7 



Fig. 5. Details of the Dies and Tools used for making the Castellated Nut shown in Fig. 4 


MOVING DIE 


I 


, I- 

I 

“r" 




H 

STATIONARY DIE 



PLAN 


%-\±_ 

// 

2 ^ 2 —^ 

.±. 


- 10'4 -^ 



LOOKING INTO MOVING DIE 


r 

c 




END VIEW F 


Machinery 


Fig. 6. Dies and Tools used in making a Locomotive Ash-pan Handle 




















































































































































































8 


' No. 114—MACHINE FORGING 

indicated at A and B in the illustration. This interesting method of making 
castellated nuts is used in the Collinwood shops of the L. S. & M. S. Railway. 
The only material wasted in the production of a castellated nut of this char¬ 
acter is the slight excess of stock formed into a fin, which must be removed, 
of course, in a subsequent operation. 

Another interesting example of castellated nut forging in which the excess 
metal is used in the formation of a washer on the nut and thus eliminates 
all waste of material, is shown in Fig. 7. The construction of the tools here 



Fig. 7. Dies and Tools used for making a Combination Washer and Castellated Nut 
which IS produced without any Waste of Stock 


illustrated is almost identical with that shown in Figs. 4 and 5 with the ex¬ 
ception of the punches and also the utilization of a cast-iron block C, for 
partly completing the construction of the gripping dies. The part of the grip¬ 
ping dies which is made from cast iron is not used as a gripping medium and 


























































































































MACHINE FORGING 


9 


hence does not need to be made from steel to provide for wear. The 
lower punch D is in this case made from machine steel and is provided 
with a tool-steel head E which is bored out and formed to a hexagon 
shape. Inserted in this is a sleeve F for forming the castellated por¬ 
tion of the nut. A punch G rough-forms the hole in the nut. The upper 
plunger H carries a punch 1 which completely forms the hole in the 



Fig. 8. Dies and Tools used in making an Enormous Upset in a 6-incli 
Ajax Universal Forging Machine 


nut by punching the bar back, and by means of the castellated washer j 
finish-forms the castellated grooves in the nut. The steps followed in 
the production of this combination castellated nut and washer are shown 
at A and B in the illustration. A 2-inch bar of wrought iron is used, 
and it requires a length of 4 inches to form the nut and washer. 

Dies and Tools Used for Making a Locomotive Trailer Pin 
The locomotive trailer pin shown at A in Fig. 8 represents about the 
maximum amount of upset which can be satisfactorily made in a 
forging machine, and in fact, is much greater than that usually recom¬ 
mended. This example which is supposed to be the largest upset ever 
made by machine methods was accomplished in the Chicago shops of 
the C. & N. W. Railway, on a 6-inch Ajax universal forging machine. 
This trailer pin is made from a 3-inch round wrought-iron bar, 26 















10 


No. 114—MACHINE FORGING 


inches long, and an excess amount of stock equal to 10% inches in 
length is put into the upset in one blow. The dimensions of the upset 
square flange are 7% inches across the flats and 10 5/16 inches across 
the corners, by 1% inch thick. The circular flange is 5% inches in 
diameter by % inch long. After the work is given the first blow with 
the plunger B, it is reheated and the work is again placed between the 
gripping dies C, only one of which is shown. The machine is again 
operated and the part given another blow which serves to close up the 



Fig. 9. Three Steps in the Formation of Ladder Treads for Freight 
Cars, accomplished in a “National” Forging Machine 


texture of the steel and eliminates the defects caused by the structure 
of the steel pulling apart during the upsetting operation. This large 
upset gives an idea of some of the possibilities of machine forging in 
making engine parts, etc. 

Bending" and Forming" Operations 

The making of ladder treads for freight cars is a good example of 
bending and forming operations that can be handled successfully in 
the upsetting and forging machine. Fig. 9 shows three of the steps 
in the production of a ladder tread which is completed to the shape 
shown at C in five operations. 

The dies and tools used for forming the feet of the ladder tread are 
illustrated in Fig. 10. The first operation is indicated at A and consists 
in cutting off a bar of %-inch iron to the required length. This is 
heated on one end, placed in the lower impression in the gripping dies 
G and H and given a blow by the plunger 7 which forms the end of 
the rod into the shape shown at B. In this operation, the stock is 






MACHINE FORGING 


11 


upset just far enough so that it will not buckle in front of the dies. 

The second operation bends and forms the stock back into a solid 
forging as indicated at C, this being accomplished in the second im¬ 
pression in the gripping dies by plunger J. The final forging operation, 
the result of which is shown at D, completes the foot, the upper impres¬ 
sions in the dies being used for this purpose; these are made the exact 
shape of the foot, and the plunger K has a pin in it which punches the 
hole in the foot to within 1/16 inch of passing through the 9/16-inch 
stock. The final operations which are performed in a bulldozer or 
other bending machine consist in bending both ends of the tread to 
the required shape. This requires two operations, which are indicated 



Fig. 10. Dies and Tools used in forming the Feet of Ladder Treads 

at E and F, respectively. Before the final bending, the forging is taken 
to an emery wheel to remove the burrs formed when forging the feet. 

The eye-bolt shown in two stages of its formation, at A and B in 
Fig. 11, is another example of a bending and forming operation ac¬ 
complished in a forging machine. This eye-bolt is made from a 1%-inch 
round wrought-iron bar, and is completed in two blows in a 3-inch 
Ajax forging machine, using the dies and tools illustrated. The con¬ 
struction of the gripping dies is rather unusual and interesting. The 
lower impression in the dies consists of two movable members G 
which slide on four rods D and are provided with tongues E which fit 
in corresponding grooves in the movable and stationary gripping dies. 
The pins, of course, act as mediums for holding these sliding members 
C in the gripping dies. The blocks C are kept out against the adjust¬ 
able lock-nuts F by open-wound coil springs G. 






















































12 


No. 114—MACHINE FORGING 



Fig. 11. An Interesting Set of Dies and Tools vised in a 3-incli Ajax Forging Machine for 

forming Eye-bolts in Two Blows 



Fig. 12. Sequence of Operations on Ford Front Axle accomplished in 
"National” 3Vi-inch Forging Machine 




































































































































































































MACHINE FORGING 


13 


The method of operation is as follows: The stock is first heated for 
a portion of its length to the correct temperature, then placed in the 
upper impression of the stationary die, being located in the correct 
endwise position by the stop of the machine. The machine is then 
operated and when the movable die closes on the work, it grips it and 
at the same time forces the heated end of the stock around pin H held 
in the stationary die. Just as soon as the dies close tightly on the 
work, punch I comes in contact with the bent end of the bar and forms 
it around the pin H, bending the work into the shape shown at A. 
The dies now open and the work Is removed and placed on the pin 
forming the center portion of the impression in the blocks C. The 



Fig. 13. Dies and Tools used for forming a Driver Brake Adjusting Bod 
Block in a 5-inch Ajax Forging Machine 


machine is again operated and as the dies close, the ram J advances 
and forces the blocks C forward, carrying the “eye-end” of the work 
along with it. 

Now as both parts of the bar—“eye-end” and body—are rigidly held 
in the gripping dies and movable blocks G, it is evident that the part 
of the bar at point K must be upset. The result of this displacement 
of the stock causes the formation of a shoulder on the bar at the base 
of the eye, formed by the circular impression M in the blocks C. 
The amount of stock required to form the boss at the base of the “eye” 
is governed by the position of the locknuts F. The ram J and gripping 
dies are made from steel castings. The four compression springs G 
are 10% inches long when extended, of % inch pitch; 5/32-inch diameter 
wire is used, and the outside diameter of the spring is 1 3/16 inch. 

Dies and Tools for Forming- a Driver Brake Adjusting- Rod Block 

A difficult forming operation accomplished in the forging machine 
is shown in Fig. 13. The part A is a driver brake adjusting rod block, 
















14 


No. 114—MACHINE FORGING 


used on freight cars. It is made of wrought iron and is completed in 
two blows in a 5-inch Ajax forging machine. The method of procedure 
in making this piece is to first cut a piece of rectangular bar iron to 
the required length and then bend it into a U-shape in the bulldozer. 



Fig. 14. A Heap of Finished Forged Coupler Pocket Filling Blocks 



Fig. 15. 5-inch Ajax Forging Machine at Work in the Collinwood Shops 
of the L. S. & M. S. Railway, set up for making Coupler 
Pocket Filling Blocks for Freight Cars 


It is then taken to the furnace where it is heated to the proper tem¬ 
perature, and a “porter” bar, about % inch in diameter, is also heated. 
This is joined to the bent piece (which is to form the block) and the 
latter is placed between the gripping dies, the,bar being used simply 















MACHINE FORGING 


15 


as a means of handling. The dies shown at B and C are provided with 
half-round impressions shown at a and 6 through which the “porter” 
bar projects. As the machine is operated, the front end of plunger D 
cuts off the “porter” bar and forces the bent piece into the impressions 
in the gripping dies. While the piece is still held in the dies, the 
machine is again operated and the work given a second blow, this, of 

course, all being done in 
the one heat. The round- 
ended plug E at the end of 
the impression in the sta¬ 
tionary die forms an im¬ 
pression in the end of the 
block and serves as a spot 
for a subsequent drilling 
operation. Work of this 
character demands a forg¬ 
ing machine in which a 
rigid gripping mechanism 
is provided, if excessive 
fins on the w'ork are to 
be avoided. The reason 
for this is that the plunger, 
in forcing the metal into 
the dies, has a tendency 
to separate them. 

Fig. 14 shows a forging 
made in practically the 
same manner as that illus¬ 
trated in Fig. 13. This 
part, a coupler pocket fill¬ 
ing block, is used on 
freight cars, and is made 
from scrap arch bars cut 
up into pieces of the de¬ 
sired length. These pieces 
are first formed into a U- 
shape in a bulldozer and 
are then brought to the 
furnace shown to the right 
in Fig, 15. Here they 
are heated to the desired 
temperature, then gripped with the tongs and placed on the shelf 
of the back stop A. The forging machine operator then lifts the 
piece from the shelf by means of a “porter” bar, and places it be¬ 
tween the gripping dies, where the forging is given two blows and 
then thrown down in the sand to cool off. Fig. 14 gives some idea 
of how this coupler pocket filling block is produced. The piece of arch 
bar which has been formed to a U-shape in the bulldozer still forms the 
end of the block, the sides or webs being formed by bending in the arch 



































IG No. 114—MACHINE FORGING 

and lapping up the open ends. This can easily be seen by referring to 
the piece A in the illustration, where the joint formed in this manner 
is clearly shown. The burrs formed on these pieces are removed in a 
subsequent operation. 

Forgring" an Automobile Front Axle 

The making of the Ford automobile front axle by forging machine 
methods is an excellent example of the general adaptability of the 
upsetting and forging machine to the manufacture of miscellaneous 
parts from carbon and alloy steels. When used in conjunction with a 
steam hammer or bulldozer, there is practically no limit to the range 
of work which can be successfully handled. One of the most recent 


Fig, 17. “National” 3*^-inch Forging Machine used in accomplishing 
the Preliminary Operations on the Ford Front Axle 

developments in forging-machine methods which should be of unusual 
interest to many manufacturers is the application of forging machines 
to the welding of machine and engine parts. This in many cases per¬ 
mits the utilization of scrap metal, thus converting practically valueless 
material into expensive machine parts. Some interesting forging opera¬ 
tions employed in the production of the Ford front axle and other 
parts, will be described in the following: 

In Fig. 16 is shown a series of interesting operations performed in 
the 314 -inch “National” forging machine shown in Fig. 17, the work 
being the front axle for the Ford automobile. This front axle is made 
from a vanadium steel bar 1% inch in diameter by 67% inches long, 
as shown at A in Fig. 16. The first forging operation consists in form- 











MACHINE FORGING 


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in this manner, but in separate heats. This operation, members. In order to form both bulges at once it is neces- 

which is also indicated at B in Pig. 12, shortens the ends sary to have the top members of these dies constructed in 

of the bar from a length of 16% inches to 13% inches, which such a manner that the blocks carrying the impressions are 

means that 2% inches of stock is put into the bulges. The free to slide forward when acted upon by the plunger held 
forging machine dies for performing this operation are in the ram of the machine. 






















































































































































18 No. 114—MACHINE FORGING 

As will be seen by referring to this illustration, one-half of the larger 
bulge is carried in block A, while the other half of the impression is 
carried in the sliding block B. In the opposite end of the sliding block 
B is provided one-half the impression for the smaller bulge, the other 
half being formed in the sliding block C. These sliding blocks B and C 
are held by tongue plates D to the main body of the top forging die in 
which they are free to slide. They are held in their outward positions 
by coil springs E and F. Coil spring E is carried on a stud held in 
sliding block B, while coil spring F is carried on a stud screwed into 
block B and fitting in a clearance hole in sliding block C. The stock, 
when heated to the correct temperature, is located in the proper posi- 



Fif. 19. “Massillon” Steam Hammer used for bringing the Ford 
Front Axle to Final Shape 


tion in the dies by block G, which is fastened by cap-screws to block C, 
and covers the hole in the dies as indicated in the end view. Block C 
is located in its proper “out” position by means of adjusting screw H, 
held in block I, fastened to the top member of the forging die. 

The stock which has been heated for a distance of about 18 or 20 
inches is placed in the impressions in the upper members of the sta¬ 
tionary gripping dies. The machine is then operated; the gripping 
dies hold the work rigidly, while plunger K advances and forces sliding 





































MACHINE FORGING 


19 


block C forward until it is in contact with block B. The forward 
movement of the ram continues until block B is forced up against 
block A, when the ram recedes, the dies open, and the forging is 
removed. It is evident that as the work is held rigidly between the 
opposing faces of the gripping dies, the advance of these sliding mem¬ 
bers can only accomplish one result, w'hich is to upset the excess metal 
and expand it into the impressions provided in the dies, thus forming 
the bulges. 

The next operation on the front axle, which is indicated on the top 
of the axle at G in Fig. 16, and also at C in Pig. 12, consists in bending 



Fig:. 20. upper and Lower Dies used in Steam Hammer shown in Fig. 19 
for finish-forming the Ford Front Axle 


the end around in order to locate the material in the required position 
for forming the knuckles of the axle. This operation is handled in the 
dies shown in Fig. 18, that member which accomplishes the work being 
formed on the top face of the top members of the dies. The bar, which 
is still in its initial heat, is laid on top of the dies and in contact with 
the stop gage L. The machine is then operated, and as the dies close, 
the impressions formed on the projection of the top die twist the end 
of the bar around and form it to the desired shape. 

The bar is now placed in the furnace and again heated to the proper 













20 


No. 114—MACHINE FORGING 


temperature. Then it is brought to the forging machine and placed in 
the lower impression in the gripping die shown in Fig. 18. The forg¬ 
ing machine is then operated, and as plunger M advances, it upsets 
and forces the work into the impressions in the lower gripping dies jV, 
forming the front axle to the shape shown at D in Figs. 12 and 16. 
This completes the operations on the front axle which are handled in 
the forging machine. After one end of the bar has been formed to 
the desired shape, the other end of the bar is heated and passed through 
the same operations. Before the front axles are passed on to the final 
drop-forging operations, the burrs and fins formed in the forging 
machine dies are removed. 

The final forming of the front axles is done under a steam hammer 
of the type shown in Fig. 19, the dies illustrated in Fig. 20 being used. 
Only one end is completed at a time; this will be seen by referring to 
the dies shown in Fig. 20. The axle is heated for a little over one-half 
its length and is placed on the lower die in the steam hammer. The 
operator is careful to locate the end of the bar so that the stock to 
form the knuckles is in the proper position in relation to the impres¬ 
sion in the die before the first blow is struck; then ten successive 
blows are struck and the axle is removed and taken to a punch press 
holding a shearing die which removes the fins. The axle is then 
brought back to the steam hammer, given a final blow and laid down 
to cool off in the sand. 

Alter one end of a batch of front axles has been finished in this 
manner, the other end is heated and carried through the operations 
described. The axles are then again taken to the furnaces, heated and 
placed in a fixture held in a punch press, where they are stretched to 
the exact length—52inches. 


CHAPTER II 


WELDING IN THE FORGING MACHINE 

There are three methods in general use for welding or joining pieces 
together in a forging machine. The selection of the one to employ 
depends largely on the shape of the work and other requirements. The 
most common method in general use is lap-welding, of which there 
are several applications. The next method in importance is pin-weld¬ 
ing. Butt-welding is as a rule used only where it is impracticable to 
handle the work in any other way. 

In regard to the materials that can be handled, wrought iron can be 
very readily welded in the forging machine, and when proper care is 
taken this can be successfully done without resorting to the use of 
fluxes except in unusual cases. Machine steel does not weld as readily 
as wrought iron, and usually it is advisable to use a welding compound 
on the faces of the parts it is intended to join. The following ingred¬ 
ients make a satisfactory flux for steel welds: To one part of sal- 
ammoniac add twelve parts of crushed borax. Heat slowly in an iron 
pot until the mixture starts to boil, then remove and reduce to a pow¬ 
der. Then apply the powder to the welding faces of the work shortly 
before removing it from the furnace, putting the work back in the fur¬ 
nace for a short period after applying the flux. Alloy steels, while they 
can be worked successfully in a forging machine, cannot be success¬ 
fully welded. As a rule, parts made from alloy steels can only be 
worked into shape by upsetting and forming. 

Lap-welding- and Forming- Operations 

A simple example of lap-welding in conjunction with a forming opera¬ 
tion is shown in Fig. 21, where the various steps in the making of a 
draw-bar hanger are illustrated at A, B and C. The first operation 
consists in cutting a 21/1 by %-inch bar of wrought iron to a length of 
19% inches—this allowing a sufficient amount of excess material to 
form the two bosses, one on each end. The bar is then heated in the 
furnace and placed in the side shear of the machine as shown at D. 
The forging machine is now operated and the tools held on the side 
shear arrangement partly cut off the bar and bend the nicked end 
around about one-quarter turn. It is then removed from the machine, 
placed on an anvil, and the bent end lapped over as shown at B, after 
which it is again put in the furnace and heated to the proper tempera¬ 
ture; it is then removed and placed in the lower impressions in the 
gripping dies, being properly located for length by the back stop E. 
The machine is then operated, completing the weld and forming the 
upset square boss on one end of the bar in one blow. After performing 
the operations described on all of the bars, the other end is handled in 
practically the same manner, using the upper impressions in the grip¬ 
ping dies and subjecting the bar to three heats instead of two. 


22 


No. 114—MACHINE FORGING 


Dies and Tools for Making: Locomotive Ash-Pan Handle 

Fig. 6 shows a locomotive ash-pan handle that is produced in a 
similar manner to the draw-bar hanger shown in Fig. 21, the opera¬ 
tions on this piece being indicated at A, B, C and D, respectively. The 
first operation is to cut off a bar A of the required length, as before 
mentioned, and bend one end over into the shape at B, putting it into 
the required condition for welding, forming and piercing in the forging 
machine. The welding and forming operations which are indicated at 
C are handled in the lower impression of the dies shown to the left of 
the illustration, the position of the work before forming being indi¬ 
cated by the dotted lines E. The lower impression is formed as shown 
in the end view of the dies at F, being provided with a draft in the 
impression of 1/16 inch on the diameter in order to facilitate the 
“fiow” of the metal and the removal of the forging from the dies. The 
punch G is made with a concave end which forms a portion of the 



Fig. 21. Making Draw-bar Hangers in a 3-inch Ajax Forging Machine 


boss and upsets the material into the desired shape at the same time. 

After being welded and formed, the work is removed from the lower 
impressions and placed in a vertical position in the upper impressions 
in the dies. Here the square hole, as indicated at D, is punched. As 
the gripping dies are made from steel castings, they would not stand 
up satisfactorily for a piercing operation, so in order to punch a clean 
hole two steel plates H and I are inserted in the movable and stationary 
members of the dies. These are so shaped that a square hole is formed 
when the dies come together. The hole is pierced by the punch J, the 
construction of which is clearly shown in the illustration. Both 
punches G and J are made from steel forgings and hardened. 

Dies and Tools for Making- Car Float Stanchion Foot 

Another interesting example of lap-welding which is used for the 
purpose of enlarging a 2-inch bar to 6 inches in diameter to form the 
head on a car float stanchion foot is illustrated in Fig. 22. This car 
part, as indicated at A and B, is made from a wrought-iron bar 2 inches 













MACHINE FORGING 


23 


in diameter, to which a rectangular block A, 6 by 3by % inch, is 
welded. Block A is first cut to the required length, and bent into a 
U-shape in the bulldozer. Then it is placed on the round bar as indi¬ 
cated at B, and the two parts are put in the furnace, where they are 
heated to a welding temperature. The parts are now quickly removed, 
given a tap to stick them together, placed in the forging machine, and 
with one blow are formed to the shape shown at C. The dies and tools 
used for this operation, which are also shown in the illustration, are 
of simple construction, consisting only of two gripping dies and one 
plunger. 

Dies and Tools for Making- Locomotive Spring- Bands 

A lap-welding operation which is handled in a different manner from 
those previously described is shown in Fig. 23. This piece, which is a 



Fig. 22 . Forging Machine Dies and Tools for making a Car Float 

Stanchion Foot 


spring band for a steam locomotive, is made from a rectangular 
wrought-iron bar 2i^ by % by 19 inches long. It is first bent into a 
U-shape, as indicated by the full lines at B, in a bulldozer. After being 
bent in the bulldozer, the work is again put in the furnace and heated 
to the proper temperature. It is then removed from the furnace, and 
by means of bending dies held in the side shear of the forging machine, 
the ends are bent into the shape shown by the dotted lines a —partly 
over-lapping each other. After this operation, the piece is again placed 
in the furnace, heated to a welding temperature, and quickly removed 
and placed between the gripping dies shown to the left. The stationary 
gripping die carries two pins D, which serve as a means for supporting 
the work before the dies close on it. The welding and forming opera¬ 
tion is accomplished by plunger B, which forms the work around the 
square impressions F in the dies, and at the same time welds the two 
ends together, forming the spring band into one piece. A particularly 


























































24 No. 114—MACHINE FORGING 

interesting feature about this job is the fact that the excess amount 
of stock formed by the overlapping ends is distributed equally along the 
front side of the forging, making it 1/32 inch thicker than the original 
rectangular bar, and thereby increasing its strength at this point. 

Dies and Tools for Making- Extension Handle for Grate Shaking- Lever 

An interesting example of lap-welding is illustrated in Fig. 24, 
where the dies and tools used for forming an extension handle for a 
grate shaking lever are illustrated. This part, as shown at A and B, 
is made from two pieces—a rectangular bar of wrought-iron 2l^ by % 
inch, which has been sheared to an angular shape on one end—and a 
loop B formed from a piece of %-inch rectangular bar iron bent into a 
U-shape in the dies illustrated to the left. The trimming of piece A 
and the bending of piece B is carried on at the same time with special 
shaped formers held to the top faces of the gripping dies. To do this, 


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Fig. 23. Forgring Machine Dies and Tools for making Locomotive Spring 

Bands 


the operator first places a piece of rectangular stock of the required 
length in the impressions in the rear member D of the stationary 
gripping die; he then takes bar A, which has been previously cut 
to the required length, and places it in the impression at the front 
end of the gripping die. Upon operating the machine, the moving die 
advances and as it carries a plunger E, it forces bar B into the suitably 
shaped impression in the stationary gripping die. At the same time 
that this operation is being accomplished, the shearing plates F and G 
carried in the stationary and movable gripping dies, respectively, shear 
off the end of bar A. 

The welding of these two parts is accomplished in the lower impres- 
































































MACHINE FORGING 


25 


sion in the gripping dies which hold the pieces in position while punch H ad¬ 
vances and upsets and welds the parts together. The two pieces are placed to¬ 
gether and put in the furnace, heated to a welding temperature, then removed 
and given a tap, so that they will stick together. They are then put in the 



Fiff. 24. Forging Machine Dies and Tools for making- Extension Handles 

for Grate Shaking Levers 


lower impression of the gripping dies and the machine operated. Then as the 
plunger H advances it enters the loop in part B, expanding it into the impres¬ 
sions in the gripping dies, and at the same time, by means of the shoulder 
on the punch, carrying forward the excess stock and distributing it equally 



























































































































26 


No. 114—MACHINE FORGING 



throughout the forging, thus joining the two parts and producing a 
perfectly welded joint. Punch H is guided when in operation on the 
work by a tongue i, which slides in a corresponding groove in the 
gripping dies, and thus prevents any side movement of the punch. 

Universal Type of Upsetting" and Forging Machine 

The miscellaneous welded and formed parts shown in Fig. 25 were 
forged in the Chicago shops of C. & N. W. Railway. The forging dies 
and tools shown in the following illustrations constitute a few of the 
many interesting examples to be found in the shop mentioned. All of 
the examples shown in Fig. 25 were produced on the 6-inch Ajax uni¬ 
versal forging machine shown in Fig. 26. 

The universal type of upsetting and forging machine shown in Fig. 


Fig. 25. Miscellaneous Examples of Lap-welding and Forming Operations 
accomplished on a 6-inch Ajax Universal Forging Machine 

26 has a much greater range of possibilities for producing machine 
made forgings than the regular upsetting and forging machines pre¬ 
viously described. This machine has all the features common to the 
regular forging machine in combination with those of a powerful 
vertical press operated independently of the other part of the machine. 
The universal forging machine is designed especially for forming such 
forgings as require squeezing, punching or trimming operations either 
before or after upsetting. This often makes it possible to prepare and 
complete large upsets and difficult shaped forgings in one handling, and 
thus utilize the initial heat. 
















MACHINE FORGING 


27 



Fig. 26. Six-inch Ajax Universal Forging Machine used in the C. & N. W. Railway 
Shops for making the Forged Parts shown in Fig. 25 



Fig. 27. Dies and Tools used in making Locomotive Main Rods in the 6-inch Ajas 

Universal Forging Machine 




















28 


No. 114—MACHINE FORGING 


It consists mainly of a double-throw crankshaft from which are 
operated two header slides—one for the standard upsetting mechanism 
and the other for the vertical press. The upper die-holder A of the 
vertical press is operated by two heavy steel side links, the lower ends 
of which connect with eccentrics on an oscillating shaft. This die- 
holder is provided with means of adjustment so that the squeezing 
dies can be brought together or separated as requirements demand. 
The lower member of the dies used in this auxiliary part of the machine 
is held on the stationary die-holder B. 

Dies and Tools for Making Spring Hangers 

An interesting example of the utilization of scrap metal for making 
engine parts is the spring hanger A, Fig. 25. This part is made from 
old arch bars 1 by 4 by 5 inches, with the dies and tools shown in 
Fig. 28. Six blocks cut off from the arch bars are piled together and 



Fig. 28. Dies and Tools for making Spring Hangers in a 6-inch Ajax 

Universal Forging Machine 

riveted as shown at A in Fig. 29, the old holes in the arch bars serving 
as a means for riveting them together. This is done to hold the 
separate blocks in place while reaching a welding heat. After the 
parts have reached the proper temperature they are taken to the uni¬ 
versal forging machine shown in Fig. 26, and placed between squeezing 
dies held in the vertical press. The machine is then operated, welding 
the pieces together and converting them into a solid block as shown 
at B in Fig. 29. 

After the separate pieces have been welded and shaped, the solid 
block is again taken to the furnace and heated to a welding tempera¬ 
ture. Then it is removed and placed between the opposing faces of the 
gripping dies B and C, Fig. 28, these being held in the forging machine 
shown in Fig. 26. The stationary gripping die B is provided with the 
shelf D on which the heated block is placed, this serving to hold it 
while the dies are coming together. As soon as the dies close on the 












MACHINE FORGING 


29 


\ 


work, plunger E advances and displaces the stock in such a manner 
as to form the tail on the end of the forging F by simply forcing the 
center portion of the block back into the rear impressions in the grip¬ 
ping dies. This is accomplished in one heat, and when the piece is 
removed from the dies it is finished complete. Vent holes G are pro¬ 
vided in the opposing faces of the dies to allow the excess metal to 
escape. 

Another example of a spring hanger forging is shown at B in Fig. 25, 
the dies and tools used being shown in Fig. 30. The first operation in 
the forging of this spring hanger is to draw the 2-inch wrought-iron 
bar A down to the shape shown at B, Fig. 31, in a Bradley steam ham¬ 
mer. This piece, after being drawn down, is heated and placed in a 



bulldozer, where it is bent into a U-shape as shown at C, the heaviest 
part of the piece being located at the bent end. The one-inch hole is 
punched through the bent end at the same time that the work is being 
formed. The body or shank of the hanger is made from a 1 by 4-inch 
piece of round edge iron D which is swaged down on a 4-inch forging 
machine to 1% inch round for a length of about 7 inches on one end, 
as shown at E. The bar is then heated, placed in the forging machine 
and upset to 2 inches in diameter in order to completely form the 
reinforced portion on the fiat part, and at the same time reduce the 
end to one inch in diameter. The reduction on the end of the bar is 
accomplished with the plunger held in the ram of the machine. 

The loop C is now placed on the reduced end of the rod as shown 
at G and is riveted cold, just enough to hold the two pieces together 
while heating for welding. The work is then raised to a good welding 
heat, and is quickly placed in the lower groove A (see Fig. 30) of the 


















































30 No. 114—MACHINE FORGING 

dies held in the 6-inch forging machine shown in Fig. 26, where the 
work is formed by plunger B (Fig. 30). The reason for doing this 
work in a 6-inch forging machine is that the plunger travel necessary 
is 14 inches, and this would be impossible on a smaller machine than 
that having a 6-inch capacity. This 14-inch travel, of course, is after 
the dies have been closed on the work. After the two pieces are welded 
together as shown at H (Fig. 31) a block a of 2-inch square iron 3 inches 
long is placed in the U-end of the forging as shown at I and a welding 
heat taken. The work is then placed in the upper groove C, Fig. 30, 



Fig. 30. Dies and Tools used in making Spring Hanger shown at B in 
Fig. 25—also illustrating Pin Welding Operation 


of the dies and as the plunger D advances it upsets the forging to the 
proper shape around the embossed center portions E, the excess metal 
flowing up through the vent holes F provided in the gripping dies. 
The flnished forging is shown at J in Fig. 31. 

Still another type of spring hanger which is completed in the forg¬ 
ing machine is shown at C in Fig. 25. This is made from a rectangu¬ 
lar bar of wrought iron which is first lapped over and then welded, 
after which the eye end is formed to shape on the forging machine. 
The square hole is rough-formed by the vertical press of the universal 
forging machine shown in Fig. 26, and is then finished in the upper 
Impression in the dies held in the horizontal part of the forging 
machine. No material is removed to form the square hole, the metal 
simply being expanded, increasing ihe width of the bar. 

















MACHINE FORGING 


31 


Dies and Tools for Making- Fork End of Main Driver-Brake Pull Rod 

The fork end of the main driver-brake pull rod shown at D in Fig. 
25 is made from a 2i/4-inch bar or round wrought iron which is first 
squeezed down flat on one end until the flattened end is 3 inches wide 
by 14 inches long. This operation is handled in the vertical head of 
the machine shown in Fig. 26. A piece of % by 3 by 14-inch wrought 
iron is laid on the flattened portion of the bar (both pieces, of course, 
being heated) so that they can be stuck together by the dies held in 
the vertical head of the universal forging machine, thus holding them 
while the welding heat is being taken. The next step in the forging 
of this fork is to increase the diameter of the rod from 2^2 to 3 inches 
square. This operation is accomplished in the upper grooves A of the 
dies shown in Fig. 32, using the plunger B for upsetting. The 3-inch 
squared end is now split for about 9 inches of its length with suitable 



tools held in the vertical head of the machine, and at the same time 
is opened up slightly. The piece is then taken to the furnace and 
heated, after which it is placed in the lower grooves C of the dies, and 
with one blow of plunger B is brought to the final shape shown at E. 

Dies and Tools for Making Slot End of Main Driver-Brake Pull Rod 

The slot end of the main driver-brake pull rod shown at E in Fig. 25 
is made as shown in Fig. 33 from two pieces a of 1 by 2^-inch flat 
bar iron 27 inches long, one piece b of 3-inch square iron 31/0 inches 
long, and one piece c of 2%-inch square iron 5 inches long. The two 
pieces a are clamped by a pair of tongs on the end where the block c is 
located and a welding heat is taken on the other end. The work is then 






















































































































32 


No. 114—MACHINE FORGING 


removed from the furnace by the tongs and quickly placed in the 
top groove of the dies. The machine is operated, and as the plunger, 
which has a punch on its front end, advances, it punches a hole in 
the work and displaces the stock, forming a boss on each side as indi¬ 
cated at B. The position of the tongs on the work is then reversed 
and the other end of the forging is heated, after which it is swaged to 
21/2 inches in diameter for a distance of 5 inches on this end to the 
shape shown at C. This operation is handled by the gripping dies 
which are provided with circular grooves located between the upper 
and lower impressions. The forging is again heated and placed in the 



Fig. 32. Dies and Tools for making Fork End of Main Driver-brake 
Pull Rod shown at D in Fig. 25 in a Forging Machine 


lower impressions of the dies, the round part entering the plunger. 
The machine is then operated, forming the forging to the shape shown 
at D. 

Butt-welding' Bottom Connecting-Rods for Freight Cars 

Butt-welding is seldom done on forging machines, owing to the 
difficulty generally experienced in successfully making this type of 
weld. The bottom connecting-rods shown at F in Fig. 34, are, however, 
produced satisfactorily by butt-welding in the Collinwood Shops of 
the L. S. & M. S. Railway. The stock for the forked ends A is sheared 
off from a bar of 2i/^ by %-inch wrought iron and bent to a U-shape in 
the bulldozer. The center portion of this connecting-rod is made from 
1%-inch round wrought-iron bars which are also sheared to the required 
length before coming to the forging machine. 

The U-shaped pieces A and bars B are now placed in a furnace where 
they are heated to a welding temperature. The operator then removes 
a rod and also a U-shaped piece and butts them together; he then 
places the pieces which are stuck together in the impressions in the 
gripping dies C and D, and operates the machine. Now as plunger E, 
which has a pointed end, advances, it forces itself through the fork 













MACHINE FORGING 


33 


into the round stock, thus intermingling the grain of the material and 
insuring a solid weld. To prevent scale from forming on the pieces to 
he welded, a small jet of compressed air is made to play on them just 
before and while the machine is operating. 

After welding, the work is removed from the gripping dies and 
placed between suitably shaped forming dies held in the side shear. 



Fig. 33. Sequence of Operations performed on the Slot End of the Main 
Driver-brake Pull Rod shown at E in Fig. 25 



The machine is then operated, forming the U-shaped end to the proper 
shape, after which the piece is thrown down in the sand to cool off. 
After all the rods have been completed in this manner, the other or 
straight end is placed in the furnace and the same procedure repeated. 
The completed bottom connecting-rods are shown at F. To prove that 












































































































































34 


No. 114—MACHINE FORGING 


this type of weld was satisfactory, numerous tests were made to break 
it at the welded joints. This was not accomplished until the testing 
machine registered a pull of 74,000 pounds, which, is equivalent to a 
tensile stress of approximately 30,000 pounds per square inch. As the 
tensile strength of wrought iron seldom exceeds 48,000 pounds per 
square inch, it will readily be seen that this type of weld would be 
satisfactory for the general run of forged work. 

The Bulldozer as an Auxilliary to the Upsetting- and Forging Machine 

Considering the fact that so many parts completed on the forging 
machine can be handled successfully only when partially formed by 
the bulldozer it may not be out of place to include a short description 
of this type of machine. Fig. 35 shows the type of bending and punch- 



Figr. 35. Ajax No. 7 High-speed Bulldozer—an Adjunct to the Forging Machine 

ing machine known as the bulldozer, which is used extensively as an 
auxiliary to the forging machine in the manufacture of many forgings. 

The construction of this type of machine is simple, consisting pri¬ 
marily of a moving crosshead A which carries one member of the 
forming dies, the other member of the forming dies being held against 
the toes B of the machine. The operations are accomplished by the 
forward travel of the crosshead, the work as a general rule being com¬ 
pleted in one travel of the head. Of course, while the machine is 
fairly simple in construction and operation, many types of interesting 
forming tools are used. 

The forming tools for the bulldozer can generally be made cheaper 
and more conveniently from cast iron, especially when they are pro¬ 
vided with hardened steel plates where any friction takes place—that 
is, those parts of the tool which actually do the forming or shaping 
should, as a general rule, be reinforced with hardened steel plates. 
This enables the tools to be renewed very cheaply, as the plates when 
worn out can be replaced by new blocks of steel. The roller type of 
tool which is carried and operated by the crosshead is the best for 
saving material and power when it is possible to use this type. How- 





MACHINE FORGING 


35 


































36 


No. 114—MACHINE FORGING 


ever, the type of tool to use depends largely on the shape to be formed 
and other requirements. In all cases where hot punching or cutting is 
done> high-speed self-hardening steel should be used for the working 
members of the tool. 

Tools for Making- Engine Main and Side Rods in the Forging- Machine 

The locomotive main rod shown at A in Fig. 27* is the largest piece 
of work ever handled in a forging machine in the Chicago shops of 
the C. & N. W. Railway. The main rod is first roughed out under a 
steam hammer and the end split before it is brought to the forging 
machine shown in Fig. 26. The roughing out of the slot and the finish¬ 
forming in the forging machine are done in one heat. In the forging 
machine the w^ork is gripped by the dies B and G, and is upset and 
formed to shape by the plunger D. 

Another good example of heavy forging done in the Ajax 6-inch uni¬ 
versal forging machine is the locomotive side rod shown at A in Fig. 
36. This side rod is made from square stock drawn down to the 
required size under the steam hammer, and is upset and formed on 
each end in the forging machine shown in Fig. 26. The gripping dies, 
only one of which is shown at B in Fig. 36, are used for forming the 
end C of the rod. It requires two operations to complete this end. 
The first operation is performed in the lower groove D of the dies and 
consists in rough-forming the slot with the plunger E. The work is 
then placed in the upper groove F and completely formed to shape by 
means of plunger G. 

The other end H of the side rod is upset and formed to shape by 
another set of dies—only one of which is shown at 7. The rod, which 
is heated to a welding temperature, is placed in the impressions in the 
gripping dies and is upset and formed to the required shape by means 
of the plunger J. These two examples of machine forging illustrate 
very well the adaptability of the forging machine to locomotive building. 


iD 3 26 


No. 67. Boilers. 

No. 68. Boiler Furnaces and Chimneys. 

No. 69. Feed Water Appliances. 

No. 70. Steam Engines. 

No. 71, Steam Turbines. 

No. 72. Pumps, Condensers, Steam and Water 
Piping. 

LOCOMOTIVE DESIGN AND RAILWAY SHOP 
PRACTICE 


No. 

27. 

Locomotive Design, Part I. 


No. 

28. 

Locomotive Design, Part II. 


No. 

29. 

Locomotive Design, Part III. 


No. 

30. 

Locomotive Design, Part IV. 


No. 

79. 

Locomotive Building. — Main and 
Rods. 

Side 

No. 

80. 

Locomotive Building. — Wheels; Axles; 
Driving Boxes. 

No. 

81. 

Locomotive Building. — Cylinders 
Frames. 

and 

No. 

82. 

Locomotive Building.—Valve Motion. 


No. 

83. 

Locomotive Building.—Boiler Shop 
tice. 

Prac- 

No. 

84. 

Locomotive Building.—Erecting. 


No. 

90. 

Railway Repair Shop Practice. 



ELECTRICITY—DYNAMOS AND MOTORS 

No. 34. Care and Repair of Dynamos and Motors. 

No. 73. Principles and Applications of Electricity. 

—Static Electricity; Electrical Measure- 
ments; Batteries. 

No. 74. Principles and Applications of Electricity. 

—Magnetism; Electric-Magnetism; Elec¬ 
tro-Plating. 

No. .75. Principles and Applications of Electricity. 

—Dynamos; Motors; Electric Railways. 
No. 76. Principles and Applications of Electricity. 

—Telegraph and Telephone. 

No. 77. Principles and Applications of Electricity. 
—Electric Lighting. 

No. 78. Principles and Applications of Electricity. 
—Transmission of Power. 

No 115, Electric Motor Drive for Machine Tools. 


HEATING AND VENTILATION 

No. 39. Fans, Ventilation and Heating. 

No. 66. Heating and Ventilation of Shops and 
Offices. 

IRON AND STEEL 
No. 36. Iron and Steel. 

No. 62. Hardness and Durability Testing of 
Metals. 

No. 117. High-speed and Carbon Tool Steel. 

No. 118. Alloy Steels. 

FORGING 

No. 44. Machine Blacksmithiiig. 

No. 45. Drop Forging. 

No. 61. Blacksmith Shop Practice. 

No. 113. Bolt, Nut and Rivet Forging. 

No. 114. Machine Forging. 

No. 119. Cold Heading. 

MECHANICAL DRAWING AND DRAFTING- 
ROOM PRACTICE 

No. 2. Drafting-Room Practice. 

No. 8. Working Drawings and Drafting-Room 
Kinks. 

No. 33. Systems and Practice of the Drafting- 
Room. 

No. 85. Mechanical Drawing.—Geometrical Prob¬ 
lems. 

No. 86. Mechanical Drawing.—Projection. 

No. 87. Mechanical Drawing.—Machine Details. 
No. 88. Mechanical Drawing.—Machine Details. 

DIE-CASTING 

No. 108. Die-Casting Machines. 

No. 109. Die-Casting, Dies and Methods. 

MISCELLANEOUS 

No. 35. Tables and Formulas for Shop and Draft¬ 
ing-Room. 

No. 110. Extrusion of Metals. 


MACHINERY’S DATA BOOKS 

Machinery’s Data Books include the material in the well-known series of Data 
Sheets published by Machinery during the past fifteen years. Of these Data Sheets, 
nearly 700 were published and 7,000,000 copies sold. Revised and greatly amplified, 
they are now presented in book form, kindred subjects grouped together. The price 
of each book is 25 cents (one shilling) delivered anywhere in the world. 


No. 1. 
No. 2. 
No. 3. 
No. 4. 

No. 5. 
No. 6. 
No. 7. 
No. 8. 

No. 9. 
No. 10. 


LIST OF MACHINERY’S DATA BOOKS 


Screw Threads. 

Screws, Bolts and Nuts. 

Taps and Dies. 

Reamers, Sockets, Drills and Milling Cut¬ 
ters. 

Spur Gearing. 

Bevel, Spiral and Worm Gearing. 
Shafting, Keys and Keyways. 

Bearings, Couplings, Clutches, Crane 
Chain and Hooks. 

Springs, Slides and Machine Details. 
Motor Drive, Speeds and Feeds, Change 
Gearing, and Boring Bars. 


No. 11. 

No. 12. 
No. 13. 
No. 14. 
No. 15. 
No. 16. 
No. 17. 
No. 18. 
No. 19. 
No. 20. 


Milling Machine Indexing, Clamping De¬ 
vices and Planer Jacks. 

Pipe and Pipe Fittings. 

Boilers and Chimneys. 

Locomotive and Railway Data. 

Steam and Gas Engines. 

Mathematical Tables. 

Mechanics and Strength of Materials. 
Beam Formulas and Structural Design. 
Belt, Rope and Chain Drives. 

Wiring Diagrams, Heating and Ventila¬ 
tion and Miscellaneous Tables. 



Machinery's 

HANDBOOK 

For MACHINE SHOP 
AND DRAFTING-ROOM 


A REFERENCE BOOK ON MACHINE 
DESIGN AND SHOP PRACTICE FOR 
THE MECHANICAL ENGINEER, 
DRAFTSMAN, TOOLMAKER AND 
MACHINIST. 


Macitixery’s Handbook comprises nearly 1400 pages of carefully edited and 
condensed data relating to the theory and practice of the machine-building 
industries. It is the first and only complete handbook devoted exclusively to 
the metal-working fiela, and contains in compact and condensed form the 
information and data collected by Maciiixehy during the past twenty years. 
It is the one essential book in a library of mechanical literature, because it 
contains all that is of importance in the text-books and treatises on mechanical 
engineering practice. Price $5.00. 

GENERAL CONTENTS 

Mathematical tables—Principal methods and formulas in arithmetic and algebra— 
Logarithms and logarithmic tables—Areas and volumes—Solution of triangles and 
trigonometrical tables—Geometrical propositions and problems—Mechanics—Strength of 
materials—Riveting and riveted joints—Strength and properties of steel wire—Strength 
and properties of wire rope—Formulas and tables for spring design—Torsional strength 
—Shafting—Friction—Plain, roller and ball bearings—Keys and keyways—Clutches and 
couplings—Friction brakes—Cams, cam design and cam milling—Spur gearing—Bevel 
gearing—Spiral gearing—Herringbone gearing—Worm gearing—Epicyclic gearing—Belting 
and rope drives—Transmission chain and chain drives—Crane chain—Dimensions of small 
machine details—Speeds and feeds of machine tools—Shrinkage and force fit allowances— 
Measuring tools and gaging methods—Change gears for spiral milling—Milling machine 
indexing—Jigs and fixtures—Grinding and grinding wheels—Screw thread systems and 
thread gages—Taps and threading dies—Milling cutters—Reamers, counterbores and 
twist drills—Heat-treatment of steel—Hardening, casehardening, annealing—Testing the 
hardness of metals—Foundry and pattern shop information—The welding of metals— 
Autogenous welding—Thermit welding—Machine welding—Blacksmith shop information 
—Die casting—Extrusion process—Soldering and brazing—Etching and etching fluids— 
Coloring metals—Machinery foundations—Application of motors to machine tools—Dynamo 
and motor troubles—Weights and measures—Metric system—Conversion tables—Specific 
gravity—Weights of materials—Heat—Pneumatics—Water pressure and flow of water— 
Pipes and piping—Lutes and cements—Patents. 


Machinery, the leading journal in the machine-building field, the originator 
of the 25-cent Reference and Data Rooks. Published monthly. Subscription, 
$2.00 yearly. Foreign subscription, $3.00. 

THE INDUSTRIAL PRESS, Publishers of MACHINERY 
140-148 LAFAYETTE STREET NEW YORK CITY, U. S. A. 













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